Systems and processes for thermoforming an article and for preparing an article for thermoforming are disclosed. The system for thermoforming can include one or more heating stations and a cooling station. The system for thermoforming can further include an article movement mechanism that can couple to an article and rotate the article inside a heating chamber, inside a cooling chamber, or both. The system for preparing an article for thermoforming can include a vessel that comprises a port, and a negative pressure generation system coupled to the port. The system for preparing an article for thermoforming can further include a compression material that forms an interior portion for receiving an article. The negative pressure generation system can cause the compression material to expand to allow for insertion of the article into the interior portion of the compression material.

Thermoforming apparatus (1) for thermoforming an article (2), preferably a permeable article (2′), comprising: an elastic membrane (3,3′); a mould (4,4′); a hot air source (5) configured to blow a hot airflow (6) towards a zone (7) of the apparatus (1) configured to receive the article (2,2′) to be thermoformed; an actuation system (8) configured to move the mould (4,4′) towards the membrane (3,3′) or vice versa to compress the heated article (2,2′) between the membrane (3,3′) and the mould (4) such that an elastic force of the membrane (3,3′) on the article (2,2′) forces the article (2,2′) to assume the shape of the mould (4).2. Thermoforming apparatus (1) according to claim 1, wherein the mould (4′) and/or membrane (3′) are perforated so to permit a transit of the hot airflow (6) from the hot air source (5) to said zone (7). Thermoforming process of an article (2,2′) in a thermoforming apparatus (1) comprising an elastic membrane (3,3′), a mould (4,4′) and a hot air source (5), comprising the steps of: heating the article (2,2′) through a hot airflow (6) blew by the hot air source (5); compressing the heated article (2,2′) between the membrane (3,3′) and/or the mould (4,4′) by uniquely moving the mould (4,4′) and the membrane (3,3′) one toward the other such that an elastic force of the membrane (3,3′) forces the article (2,2′) to assume the shape of the mould (4,4′).

An apparatus for hot drape forming a part includes a plurality of pyrometers, a bladder covering a formable material, and a pyrometer control medium positioned between the plurality of pyrometers and the formable material. The plurality of pyrometers are configured to measure a temperature of the pyrometer control medium.

An apparatus for hot drape forming a part includes a plurality of pyrometers, a bladder covering a formable material, and a pyrometer control medium positioned between the plurality of pyrometers and the formable material. The plurality of pyrometers are configured to measure a temperature of the pyrometer control medium.

The instant application discloses, among other things, ways to manufacture reduced density thermoplastics. A rapid foaming process which may create a polymer product by saturating thermoplastic sheet or preforms, heating, and then forming into final shape, is described. The polymer product may include an integral solid skin. This method may be utilized with any thermoplastic. The material handling, saturation methods, and end products are also described.

A thermoplastic forming tool includes a wand that includes a handle, a tip, and a conduit coupling the handle to the tip. The tip includes a heating element, a forming shoe, and a forming shoe support. During use, heat from the heating element heats the forming shoe to a temperature at or above the glass transition temperature of a thermoplastic polymer. The thermoplastic forming tool may be used to apply a thermoplastic material to a surface.

Methods for thermal forming an object are provided. In some embodiments, a method includes reading a mold identifier located on or in a mold, and determining mold process information from the mold identifier, the mold process information including heating information. The method can include heating a thermoformable material according to the heating information by adjusting power of one or more independently controllable heat sources. The method can also include monitoring one or more temperatures from a plurality of temperature sensing elements operably coupled to different areas of the thermoformable material. The thermoformable material can be heated according to the heating information and in response to the one or more monitored temperatures such that each of the different areas of the thermoformable material reach a respective desired temperature. The method can further include disposing the heated thermoformable material over at least a portion of the mold to form the object.

A thermoforming method includes forming a skin comprising a plurality of plies thermoplastic resin and fiber, securing an edge of the skin to a mandrel, heating, via a heating element, the skin to a forming temperature, moving a thermoforming apparatus with respect to the mandrel, rolling at least one roller of the thermoforming apparatus along the skin in a direction away from the clamped edge of the skin in response to the thermoforming apparatus moving with respect to the mandrel, and in response to the at least one roller of the thermoforming apparatus rolling along the skin, compressing the skin between the at least one roller and the mandrel, consolidating the plurality of plies of material, and bending the skin to conform to a shape of the mandrel. The consolidated and formed skin is then cooled and removed from the mandrel.

A thermoforming method includes forming a skin comprising a plurality of plies thermoplastic resin and fiber, securing an edge of the skin to a mandrel, heating, via a heating element, the skin to a forming temperature, moving a thermoforming apparatus with respect to the mandrel, rolling at least one roller of the thermoforming apparatus along the skin in a direction away from the clamped edge of the skin in response to the thermoforming apparatus moving with respect to the mandrel, and in response to the at least one roller of the thermoforming apparatus rolling along the skin, compressing the skin between the at least one roller and the mandrel, consolidating the plurality of plies of material, and bending the skin to conform to a shape of the mandrel. The consolidated and formed skin is then cooled and removed from the mandrel.

Systems and methods for forming 3D plastic parts that are cost effective in low volume, have excellent fit and finish, and use many components from 2D construction are disclosed. The systems and methods involve selecting a design and modelling the design. The design comprises 2D and 3D components of plastic parts. A 3D forming buck corresponding to the 3D component is manufactured. At least one of a 2D part and the 3D forming buck may be heated. The 2D part may be loaded onto the 3D forming buck for a predefined period of time. The 3D part formed after the loading may be separated from the 3D forming buck. The 3D part is the 2D part generally having taken the shape of the 3D forming buck. The 3D part may be cooled to obtain an end product.